Receptacle for enclosing low-voltage electronic devices in a wall

ABSTRACT

A receptacle for enclosing low-voltage electronic devices and maintaining the integrity of a vapor barrier. The receptacle includes a base, and four side walls. Each side wall is joined to two adjacent side walls to form a perimeter wall. The perimeter wall is joined to the base and extends from it in a generally perpendicular fashion. The perimeter wall and base delineate a generally rectangular enclosure with five closed sides and one open side. A mounting flange is joined to the four side walls and extends from them in a generally perpendicular fashion. The receptacle is positioned within a wall of a building so as to allow at least one flange direct contact with a structural member. The structural members of the wall and the receptacle are both covered with a barrier film. The barrier film is sealingly attached to the flange. A hole is created through the barrier film within the confines of the receptacle so that a low voltage electronic device can be mounted in the wall without compromising the vapor barrier of the building.

This application is a continuation of U.S. application Ser. No.11/321,678, filed Dec. 29, 2005, which is a continuation of U.S.application Ser. No. 10/677,020, filed Oct. 1, 2003, which is acontinuation of U.S. application Ser. No. 09/516,199, filed Feb. 29,2000, now U.S. Pat. No. 6,660,936, which is a continuation of U.S.application Ser. No. 09/193,876, filed Nov. 18, 1998, now U.S. Pat. No.6,031,181.

FIELD OF THE INVENTION

The present invention relates generally to components for buildingconstruction. More particularly, the present invention relates toreceptacles for enclosing low voltage electronic devices.

BACKGROUND OF THE INVENTION

With the rising cost of energy, efforts have been made to provide homesand other buildings with insulation which will more efficiently preventthe loss of heat to the outside. Modern building techniques include theinstallation of a vapor barrier in the walls of homes or otherbuildings.

The vapor barrier contains warm, moist air inside the building. If warmair from inside the building penetrates the vapor barrier, moisture fromthis air may condense inside the walls and ceilings of the building.This condensed moisture can promote mold growth and cause buildingmaterials to degrade. The loss of warm air from the inside of thebuilding to the outside of the building also increases the cost ofheating the structure.

When mounting speakers, keypads and other low voltage electronic devicesin the wall or ceiling of a house or other building it is desirable toprotect the low voltage devices from exposure to dirt, debris frombuilding materials and other substances which may cause these devices todeteriorate. Installers who place low-voltage electronic devices in thewalls of structures often use standard building materials to fabricate a“custom-built” enclosure at the installation site. To comply with modernbuilding requirements, these custom-built enclosures must besubstantially impervious to warn, moist air, and they must be sealinglyconnected to the existing vapor barrier of the structure. A great dealof skill is required to assemble an enclosure at a work site which willaccomplish these goals. Even when an installer is highly skilled, thistask is very time consuming.

SUMMARY OF THE INVENTION

A receptacle enclosing low voltage electronic devices and maintainingthe integrity of a vapor barrier. The receptacle includes a base andfour side walls. Each side wall is joined to two adjacent side walls toform a perimeter wall. The perimeter wall is joined to the base andextends from it in a generally perpendicular fashion. The perimeter walland base delineate a generally rectangular enclosure with five closedsides and one open side.

The base of the receptacle includes a pattern of concentric geometricshapes. When a portion of the base is seen through a hole cut in a wall,this pattern provides the installer with visual indicators which allowthe installer to determine the location of the hidden portions of thereceptacle.

The receptacle also includes a plurality of wire located dimples. Thematerial thickness of the wire locator dimples is generally thinner thanthe thickness of the perimeter wall and the base. The wire locatordimples are useful for creating a hole which will allow a wire to enterthe receptacle. Removing the wire locator dimple from the receptacleusing a knife or other cutting tool creates a small circular hole in thereceptacle. When the desired length of wire is pulled through the hole,the hole may be sealed using any commercially available sealant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a receptacle for enclosing low voltageelectronic devices in a wall;

FIG. 2 is a cross sectional view of a receptacle for enclosing lowvoltage electronic devices in a wall;

FIG. 3 is a plan view of a receptacle positioned inside a wall;

FIG. 4 is a plan view of an alternate embodiment of a receptaclepositioned in a wall;

FIG. 5 is a third embodiment of receptacle positioned in a wall;

FIG. 6 is a cross sectional view of a wall with a receptacle forenclosing low voltage electronic devices positioned inside of it; and

FIG. 7 is a plan view of a wall with a hole cut through the wall forfastening a low voltage electronic device.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to the figures, in which like element numbersrefer to like elements throughout. FIG. 1 is a perspective view of areceptacle shown generally by element number 10. Receptacle 10 includesa base 12, and four side walls 14, 16, 18, and 20. Each side wall isjoined to two adjacent side walls to form a perimeter wall 11. Perimeterwall 11 is joined to base 12 and extends from base 12 in a generallyperpendicular fashion. Perimeter wall 11 and base 12 delineate agenerally rectangular enclosure with five closed sides and one openside.

A mounting flange 22 is joined to side walls 14, 16, 18, and 20.Mounting flange 22 is comprised of side flanges 24 and 26, top flange 28and bottom flange 30. Flanges 24, 26, 28, and 30 extend in a generallyperpendicular fashion from side walls 14, 16, 18, and 20 respectively.

Base 12 includes a pattern of concentric geometrical shapes showngenerally at 32. As shown in FIG. 1, the center of pattern 32 isgenerally aligned with the center of base 12. Pattern 32 in FIG. 1 is apattern of concentric circles. It is to be understood that anothergeometric shape could be chosen for pattern 32 without deviating fromthe spirit or scope of this invention. For example, pattern 32 could bea pattern of polygons, such as triangles, or squares.

Pattern 32 may also be created on base 12 using a variety of techniques.For example, pattern 32 could be injection molded with a series ofraised lines which constitute pattern 32. Alternately, pattern 32 couldbe printed on a label and the label could be adhered to base 12. Pattern32 could also be printed directly onto base 12 using conventionalprinting methods such as pad printing or screen printing.

In a preferred embodiment, pattern 32 is formed by alternating ridges 34and grooves 36 in base 12 (best shown in FIG. 2). Ridges 34 and grooves36 serve to stiffen base 12 in addition to creating pattern 32.Stiffening of base 12 is particularly valuable when receptacle 10 isused to house audio speakers. If base 12 was substantially flexible, anaudio speaker may cause it to vibrate and create undesirable noise.

Receptacle 12 includes a plurality of wire locator dimples 33A, 33B,33C, 33D, and 33E. As best shown in FIG. 2, wire locator dimples 33A,33B, 33C, 33D, and 33E each are comprised of a localized projectionformed from the same material as the wall but extending away from thewall. The material thickness of wire locator dimples 33A, 33B, 33C, 33D,and 33E is generally thinner that the material thickness of side walls14, 16, 18, and 20, and base 12.

Wire locator dimples 33A, 33B, 33C, 33D, and 33E are useful for creatinga hole allowing a wire 62 to pass through one wall of receptacle 10. Forexample, if an installer intends to pass wire 62 through wall 20, aknife or other cutting tool may be used to cut off wire locator dimple33D. Cutting off wire locator dimple 33D creates a small circular holein wall 20. When installing a low-voltage electronic device inreceptacle 10 wire 62 will be pulled through this hole. When the desiredlength of wire 62 is pulled through the hole, the hole will be sealedusing any commercially available sealant such as silicone caulk oracrylic caulk. Sealing the hole which allows wire 62 to enter receptacle10 is necessary in order to maintain a continuous vapor barrier withinwall 50. Wire locator dimples 33A, 33B, 33C, 33D, and 33E allow aninstaller to quickly create a small round hole of uniform size andshape. Only a small amount of sealing material is require to seal thissmall uniformly shaped hole after wire 62 has been positioned. Thissaves time for the installer and improves the integrity of the vaporbarrier.

In one embodiment of receptacle 10, a layer of pressure sensitiveadhesive 38 is applied to flange 22 as shown in FIG. 2. Pressuresensitive adhesive 38 may be covered with a release liner 40 to preventpressure sensitive adhesive 38 from adhering to any objects whilereceptacle 10 is transported and stored prior to use. Release liner 40may be comprised of a layer of paper or plastic film treated with arelease agent. Release liner materials of this type are well known inthe art and may use silicone or fluoropolymer based release agents.

Receptacle 10 may be made from any substantially rigid material. Thepreferred material for receptacle 10 is a thermoplastic material such asABS or PVC. Thermoplastic materials are low in cost and they can beeasily fabricated using conventional injection molding, or thermoformingprocesses. In many applications a flame-retardant thermoplastic materialwill be preferred.

A portion of a building wall 50 is illustrated in FIG. 3 with theinventive receptacle 10 installed. Wall 50 includes structural members52A, 52B, and outer layer 54. Structural members 52A, 52B may becomprised of a number of commonly used building materials includingsteel, aluminum, and wood. A number of materials may also be used tofabricate outer layer 54 including plaster, wood, acoustic tiles, gypsumboard, or a wood fiber composite material. In the art gypsum board issometimes referred to as drywall, or by the trademarked brand nameSHEETROCK. A barrier film 56 is positioned directly behind outer layer54 in wall 50. Barrier film 56 may be any low cost, thin material whichis substantially impervious to air and water vapor. Barrier film 56 ispositioned in wall 50 to prevent the passage of warm moist air from theinside of the building to the outside of the building. To accomplishthis goal completely, any holes made in barrier film 56 is preferablycompletely sealed. In the art the walls of a building are assembled toinclude a continuous sealed layer which is comprised of multiple sheetsof barrier film 56 sealingly attached along their edges. In the art,this continuous sealed layer is referred to as the vapor barrier. Anobjective of the present invention is to provide method of installinglow-voltage electronic devices in a wall while maintaining the integrityof the vapor layer.

Receptacle 10 is positioned in wall 50 so that side flanges 24 and 26overlap structural members 52B and 52A respectively. A plurality offasteners 58 have been used to attach side flanges 24 and 26 tostructural members 52B and 52A. In the embodiment shown in FIG. 3fasteners 58 are depicted as staples, however it should be understoodthat other fasteners could be used without departing from the spirit andscope of this invention. For example, fasteners 58 could be screws,nails, or rivets.

In an alternate embodiment receptacle 10 may be positioned in wall 50 sothat top flange 28 and bottom flange 30 overlap structural members 52A,52B. In a preferred embodiment the length of side walls 14, 16, 18, and20 are selected so that receptacle 10 will fit between structuralmembers 52A, 52B which have be placed a distance part which is commonlyused in the art. For example, the length of side walls 18 and 20 may beselected so that receptacle 10 will fit between structural members whichhave been placed on 16 inch centers and the length of side walls 14 and16 may be selected so that receptacle 10 will fit between structuralmembers which have been placed on 24 inch centers.

An end 60 of wire 62 is disposed inside receptacle 10. Wire 62 passesthrough a wire entry hole 61 in side wall 18 of receptacle 10. A wirecoil or bundle 64 is formed of wire 62 and is disposed immediatelyoutside one wall of receptacle 10. Although FIG. 3 illustrates wire 62passing through side wall 18, it should be noted that wire 62 may passthrough any side wall 14, 16, 18, 20, or base 12 without departing fromthe scope or spirit of this invention.

It should also be noted that although the specific embodimentillustrated in FIG. 3 depicts receptacle 10 installed in a wall,receptacle 10 may be installed in other portions of a building withoutdeparting from the spirit or scope of this invention. For example,receptacle 10 may be mounted in a ceiling to house an audio speaker.

FIG. 4 is a plan view illustrating a receptacle 110. Receptacle 110 ispositioned in wall 150 so that side flanges 124 and 126 overlapstructural members 152B and 152A respectively. A plurality of fasteners158 have been used to attach side flanges 124 and 126 to structuralmembers 152B and 152A.

A wire 162 extends through a wire entry hole 161 in side wall 118 ofreceptacle 110. A wire bundle 164 and a wire end 160 are both disposedinside receptacle 110. Wire entry hole 161 was created by cutting off awire locator dimple (not shown). Wire entry hole 161 is covered by seal166 which is adhesively bonded to both wire 162 and wall 118 ofreceptacle 110. Seal 166 is created by dispensing a sealant 168 ontoboth wire 162 and wall 118 in the vicinity of wire entry hole 161, thenallowing sealant 168 to cure. Sealant 168 may be any one of a number ofcommercially available materials including silicone caulk and acryliccaulk. Seal 166 ensures the integrity of the vapor barrier by closingwire entry hole 161 which was made in wall 118 to accommodate wire 162.

A plurality of mounting brackets 172, 174 are disposed in receptacle110. Mounting brackets 172, 174 may be attached to receptacle 110 withmechanical fasteners (not shown) such as rivets or screws. Mountingbrackets 172, 174 may also be adhered to receptacle 110 with an adhesive(not shown). Mounting brackets 172, 174 provide a convenient place toattach low-voltage electronic devices which are being housed inreceptacle 110.

FIG. 5 is a plan view of a receptacle 210 positioned in a wall 250. Awire 262 extends through seal 268 and through a wire entry hole 261 in aside wall 218 of receptacle 210. Seal 266 is adhesively bonded to bothwire 262 and wall 218. Seal 266 is created by dispensing a sealant 268onto both wire 262 and wall 218 in the vicinity of wire entry hole 261,then allowing sealant 268 to cure. Sealant 268 may be any one of anumber of commercially available materials including silicone caulk andacrylic caulk.

A zig/zag or serpentine wire pattern 270 is disposed inside ofreceptacle 210. Serpentine wire pattern 270 is comprised of a length ofwire 262 which has been bent into the shape shown in the FIG. 5.Fasteners 269, such as staples preferably loosely hold wire pattern 270in place until the electronic device is installed.

FIG. 6 is a section of wall 50 taken along section line A-A in FIG. 3.Receptacle 10 is illustrated in FIG. 6 in a position between structuralmembers 52A and 52B. Barrier film 56 is shown covering receptacle 10.Flange 22 of receptacle 10 is sealingly connected to barrier film 56. Anumber of methods may be used to accomplish this seal. In one embodimentpressure sensitive adhesive layer 38 is pre-applied to flange 22 andcovered with release liner 40. Release liner 40 is removed prior tocovering receptacle 10 with barrier film 56. When barrier film 56 ispositioned over receptacle 10 it will readily adhere to pressuresensitive adhesive layer 38 and form a sealed connection with flange 22.

An alternate method for sealing barrier film 56 to flange 22 is to applyan adhesive to flange 22 just prior to covering receptacle 10 withbarrier film 56. Spray on adhesives suitable for this purpose arecommercially available from 3M Company (St. Paul, Minn.). Finally,sealing tape may also be use to seal barrier film 56 to flange 22.

FIG. 7 is a plan view of wall 50 taken from the point of view of lineB-B shown in FIG. 6. A hole 80 has been cut through outer layer 54 andbarrier film 56. Geometric pattern 32 of receptacle 10 is visiblethrough hole 80. Geometric pattern 32 provides the installer of a lowvoltage electronic device with a visual reference point. After lookingat geometric pattern 32, the installer knows which direction he or shemust reach to find wire end 60.

Referring to FIG. 7 and FIG. 3, the preferred steps used to enclose alow-voltage electronic device and maintain the integrity of a vaporbarrier are as follows:

1. Choose which of the wire locator dimples is the most convenient placefor wire 62 to enter receptacle 10.

2. Cut off the wire locator dimple to create wire entry hole 61.

3. Position receptacle 10 within wall 50 so that at least one flange isin direct contact with a structural member.

4. Secure the flange to the structural member.

5. Thread wire 62 through wire entry hole 61 in receptacle 10.

6. Place barrier film 56 over structural members 52A, 52 B andreceptacle 10.

7. Seal barrier film 56 to flange 22 of receptacle 10.

8. Complete the assembly of the wall by positioning outer layer 54 overbarrier film 56.

9. Connect a radio frequency transmitter to wire 62.

10. Use a radio frequency receiver to determine the approximate locationof wire end 60; in this approximate location, create hole 80 throughbarrier film 56 and outer layer 54.

11. Visually examine pattern 32 to determine the location of wire end 60relative to hole 80.

12. Reach inside hole 80 with one hand and retrieve wire 62 by graspingwire end 60.

13. Pull out the desired length of wire 62 and attach wire end 60 to thelow-voltage electronic device which is being installed.

14. Seal wire entry hole 61 in enclosure 10 using a sealant such assilicone caulk or acrylic caulk.

15. Complete the installation by fastening the low-voltage electronicdevice to outer layer 54.

Numerous advantages of the invention covered by this document have beenset forth in the foregoing description. It will be understood, however,that this disclosure is, in many respects, only illustrative. Changesmay be made in details, particularly in matters of shape, size, andarrangement of parts without exceeding the scope of the invention. Theinventions's scope is, of course, defined in the language in which theappended claims are expressed.

1. An electrical component enclosure comprising: a wall of a structurecomprising structural support members and an outer layer; and areceptacle positioned between the support members, the receptaclecomprising a base wall and a perimeter wall extending from the base wallforming a cavity with an open side, the base wall having a surfaceincluding a corrugated pattern of concentric ridges and valleys whereinthe corrugated pattern of concentric ridges and valleys are generallycentered in the surface of the base wall, and the corrugated pattern ofconcentric ridges and valleys substantially occupies the surface of thebase wall; and wherein the outer layer of the wall of a structureextends across the open side of the receptacle
 2. The electricalcomponent enclosure of claim 1, further comprising a vapor barrierpositioned between the outer layer and the receptacle.
 3. The electricalcomponent enclosure of claim 2, wherein the vapor barrier is adhered tothe receptacle.
 4. The electrical component enclosure of claim 1,wherein the receptacle is formed of a thermoplastic material.
 5. Theelectrical component enclosure of claim 1, wherein the receptacle isformed of a flame-retardant thermoplastic material.
 6. An electricalcomponent enclosure comprising: a wall of a structure comprisingstructural support members and an outer layer; and a receptaclepositioned between the support members, the receptacle comprising a basewall and a perimeter wall extending from the base wall forming a cavitywith an open side, the base wall formed of a flame-retardantthermoplastic material; wherein the base wall of the receptacle includesa pattern of geometric shapes wherein the pattern of geometric shapes iscentered in the base wall, and the pattern of geometric shapessubstantially occupies the base wall; and wherein the outer layer of thewall extends across the open side of the receptacle.
 7. The electricalcomponent enclosure of claim 6, further comprising a vapor barrierpositioned between the outer layer and the receptacle.
 8. The electricalcomponent enclosure of claim 7, wherein the vapor barrier is adhered tothe receptacle.
 9. The electrical component enclosure of claim 6,wherein the pattern of geometric shapes is a corrugated pattern ofridges and valleys.
 10. The electrical component of claim 9, wherein thecorrugated pattern of ridges and valleys substantially occupies asurface of the base wall.